Water-in-Oil Spread Processing With Recirculation and Low-Heat Mixing
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Solution Overview
Problem
Existing processes for manufacturing fat-continuous spreads are energy-intensive, limited in fat choices, and suffer from re-workability issues, leading to product deterioration and inhomogeneity.
Innovation Solution
A process combining a stirred tank with recirculation means for mixing an oil phase and fat powder, followed by combining the aqueous phase outside the tank to form a pre-emulsion, using a dynamic mixer, without heating the entire composition, and maintaining temperatures below 40°C to preserve structuring properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the complete composition is subjected to heating and cooling steps to prepare the spread, then the structuring fat can be properly incorporated and emulsion formed, but energy consumption increases significantly
Solution Approach 1:
The structuring fat is pre-crystallized before being incorporated into the emulsion, eliminating the need to heat the complete composition. The pre-formed fat crystals are mixed with liquid oil and aqueous phase at ambient or refrigerated temperatures, achieving proper emulsion structure without energy-intensive heating and cooling cycles
2Reliability
If a structuring agent with high melting point is used to stabilize the emulsion, then emulsion stability improves, but mouthfeel deteriorates due to unsatisfactory melting properties
Solution Approach 1:
Instead of changing the melting point parameter of the structuring agent, the invention changes the physical state parameter by pre-crystallizing the fat and controlling the crystallization process to form a specific crystal network structure that provides both stability and desirable mouthfeel at lower temperatures
3Object-affected harmful factors
If the structuring agent with low melting point is used to achieve good mouthfeel, then melting properties improve, but emulsion stability deteriorates
Solution Approach 1:
The invention utilizes controlled phase transition by pre-crystallizing the structuring fat to form a stable crystal network that remains stable at emulsion preparation temperatures, while the crystal structure itself provides the desired melting characteristics at mouth temperature, resolving the contradiction between stability and mouthfeel
4Productivity
If the ready dispersion is stored in buffer tanks or left standing in the line to handle packaging interruptions, then packaging continuity is maintained, but product consistency deteriorates and waste increases
Solution Approach 1:
The process enables continuous operation by eliminating the need for buffer storage. The fat powder mixing and emulsion formation can proceed continuously at controlled temperatures, and the product can be held in a liquid state without consistency changes, allowing direct feeding to packaging without interruptions or waste
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces energy consumption, expands fat choices, and improves re-workability, ensuring consistent product quality and stability.
Implementation Method 1
mixing an oil phase and a fat powder into a fat slurry in a stirred tank
Implementation Method 2
combining the aqueous phase with the fat slurry and/or pre-emulsion outside the stirred tank in the recirculation means, to form a pre-emulsion
Data Source
AI summary
A process for manufacturing an edible water-in-oil spread, which process has the advantages of the cool blending process for manufacturing spreads, with improved rework capabilities. This is achieved by combining a stirred tank with recirculation means.